Hi
@Sub Woofer . I would probably wait for responses from others more versed in these things. (As usual, I am too verbose and take so long to write things, I think you might be getting some).
The Pups, Fatdog, and the Dogs (I suspect) are very flexible, so there are a lot of options.
a) I don't know if this might be jumping ahead too quickly, but I wonder if you might have an empty "test" USB drive available to try a new option that has become available in Fatdog64-811? If it is to your liking you could then use it for your "main" USB (if you haven't already set anything up). In Fatdog64-811 (it has to be 811, not an earlier version), in the Fatdog Help section, there is an entry describing a way to setup up a USB drive so that it will boot in both UEFI and Legacy/CSM modes (of course, I have forgotten the title, but it is directly under the listings for installing Fatdog to UEFI setups). If you were interested in this option then there would be a need for exercising care, as copying the image to the USB drive will destroy any existing data, and getting the destination device for the 'dd' command wrong could wipe out data etc. on the wrong device (maybe even destroy the device if I have read things correctly). I only mention this option as I have started using it and it does present many advantages.
Otherwise,
b) I guess the first thing to ask is whether you might have already begun setting up the Philips USB drive?
c) If you were waiting for advice first then
you would not need so large a boot partition, nor would you need to install Grub4DOS in each partition (unless you wanted to be chain loading for some reason).
If you are intending to use Grub4DOS to boot the USB drive then it is probably best to use GParted from a Puppy/Fatdog etc. to set up the partitions. The reason for this is that Grub4DOS is 32 bit and doesn't support the newer 64 bit extensions to ext4 filesystems. From what Bigpup has posted elsewhere, the GParted implementations in the Pups etc. will generate ext4 filesystems that are supported, and therefore can be booted using Grub4DOS.
I personally tend to like to label the partitions as well, but, naturally, that is up to you.
Here I am a bit rusty, as I have tended to just do things manually, so if something doesn't gel, it's probably my memory messing things up, or that I am out of touch with things.
The usual method of setting up a Pup is to use a frugal installation. I have have presumed that would be the case in what follows. If you intend to use another method then the partitioning setup would need to be modified accordingly.
For USB drive installations I have tended (and it is just my preference) to set up an 8 Mb ext2 (or 3) partition with the boot flag active (if I don't forget, otherwise the Grub4DOS installer reminds me
). Then another partition, or partitions for the Puppy/Fatdog etc. files. These files are placed in folders/directories in the partition. For example, the second partition might have something like a folder named "BionicPup64-USB (or version number etc- it is only a name). If you use the Universal Installer it is likely to generate a name that you can then accept, or modify. Silly me. Using the Universal Installer in the first instance would probably be the best approach as it would set up the directory and copy the files as required, and you can use that set up as a template if you decide to do things manually from there. After the Universal Installer has done it's stuff it may come up with a dialog box with the Legacy and Grub4DOS boot parameters. You can then invoke the Grub4DOS installer and after it has finished, modify the menu.lst entries, if necessary.
It should be noted that I have probably been fortunate with the hardware that I have.
From some posts I have seen, I suspect that Bigpup might prefer to set up a 512(?-I think) MB Fat32 boot partition rather than the smaller ext2 type mentioned above (along of course, with a separate linux partition for the Puppy files). Bigpup has a wider experience both with hardware, and with helping others with hardware boot issues, so you might want to go with that approach.
There are a multitude of options and all of us have our preferences. As pointed out by Puddlemoon you don't need a separate boot partition. However, there could be a case for the separation if you decide to follow the approach that I think Bigpup might suggest. The reason is that Fat32 might be more compatible with some BIOS's, but Linux filesystems give you more flexibility when saving etc.
As indicated by Puddlemoon, you can have a number of Pups on the one partition, the files for each in their own directory/folder.
Along with Puddlemoon's suggestion of checking the speed of an installation on the hard drive, there is the consideration of where to place the save file/folder for each pup, or which option you might prefer to use. When you exit a Puppy (if a save file/folder, or multi-session set-up is not in use) it will ask if you want to save the session.
The save file/folder (or multi-session files) hold the changes you make. For the larger set-up you describe it might be best to use a save folder (a save file is of a set size- it can be adjusted, but a folder is probably easier).
The directory/folder that holds the related Puppy files is likely to be the default folder selected for placement of the save file/folder, but you can adjust it.
The decision regarding where to place the save file/folder rests with you. What level of portability do you want? If the save file/folder is on the USB then you have the changes with you, but they may include machine specific things as well (I could be wrong but I think this might be the case). Hence it may not be best using the USB key on another device. If you decide the saves should go on the hard drive then there would be an advantage in setting up a partition with a linux filesystem on the hard drive (you might already have this if you decided to make frugal installs to the hard drive). Save folders (should you want to take advantage of the flexibility regarding size etc.) are only available when using a Linux filesystem. It is my understanding that save files might not be restricted in this way.
Of course, if you decide to place the saves on the hard drive, while booting from the USB drive, then the save file/folder should normally be found when using the USB drive on that machine. If however, you use the USB drive to boot another machine, the base Puppy files will load without any modifications (i.e. without the changes you have made).
Apologies. There is a lot to this and I tend to be really verbose.
Thanks.